CN115427903A - Dynamic production planning method for continuous casting facility - Google Patents

Dynamic production planning method for continuous casting facility Download PDF

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Publication number
CN115427903A
CN115427903A CN202180027122.8A CN202180027122A CN115427903A CN 115427903 A CN115427903 A CN 115427903A CN 202180027122 A CN202180027122 A CN 202180027122A CN 115427903 A CN115427903 A CN 115427903A
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production
strand
casting
parameters
plan
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Chinese (zh)
Inventor
克里斯托夫·艾格纳
凯·安克曼
丹尼尔·富赫舒伯
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Primetals Technologies Austria GmbH
Primetals Technologies Germany GmbH
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Primetals Technologies Austria GmbH
Primetals Technologies Germany GmbH
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    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Programme-control systems
    • G05B19/02Programme-control systems electric
    • G05B19/418Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
    • G05B19/41865Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/12Accessories for subsequent treating or working cast stock in situ
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/12Accessories for subsequent treating or working cast stock in situ
    • B22D11/126Accessories for subsequent treating or working cast stock in situ for cutting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/16Controlling or regulating processes or operations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/16Controlling or regulating processes or operations
    • B22D11/163Controlling or regulating processes or operations for cutting cast stock
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/32Operator till task planning
    • G05B2219/32042Halting, initiating or resuming production of a product on order
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/32Operator till task planning
    • G05B2219/32083Alternative, variant operation planning, revision specification of product
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

The present invention relates to the field of continuous casting installations in the metal production industry. The object of the present invention is to provide a method which guarantees a product which is as cost-effective as possible with a minimum of waste and reduced storage costs. This object is achieved by comparing the nominal production parameters with the actual production parameters, and if the nominal production parameters deviate from the target production parameters, the actual production parameters are used to create a casting flow map. The strand map comprises a strand (7) that has been cast but not yet cut, and a strand (7) that is produced at least as a function of the residual weight in the tundish and preset parameters. With the aid of the calculated casting flow map, a check is made within a preset production plan and, if possible, a new production plan is created. If a solution cannot be found from the preset production plan, the casting flow image is transferred to a production planning system (4). The production planning system (4) creates a new production plan from all existing orders according to preset optimization criteria. The new production plan is then transmitted to the production system (3).

Description

Dynamic production planning method for continuous casting facility
Technical Field
The present invention relates to the field of continuous casting installations in the metal production industry.
In one aspect, the present invention relates to a dynamic production planning method for a continuous casting facility having a production system and a pre-set production plan for casting a strand.
In another aspect, the present invention relates to a continuous casting facility.
Furthermore, the invention includes a computer program for executing the dynamic production planning method for a continuous casting facility.
Background
Continuous casting is a continuous process for manufacturing semifinished products. In this case, liquid steel produced, for example, in a steel mill is cast in a cooled mold and cooled in the strand guide until it solidifies completely.
The solidified strand is cut in sections on a torch cutter according to a production order and transported away for further processing.
Production plans for the entire production line are created in the MES (manufacturing execution system) or PPS (production planning system) system, also called level 3 (L3) system, which incorporates the existing customer orders according to rules, which are stored in the order management system, level 4 (L4) system.
The created production plan is then transmitted as a production order to the individual units.
Based on the received order data, the process optimization system, the level 2 (L2) system, calculates the generation rules and the product plan. The die format and the length specification of the torch cutter are set on the basis of the calculated product plan.
Production can be carried out according to the calculated product plan as long as the process operates according to the product specifications of the respective steel product.
However, due to process technology framework conditions, process events, facility failures, and deviations in steel supply, operations outside of product specifications can occur.
Current process optimization systems are able to identify deviations from product specifications and set appropriate rejection ranges and quality assessments.
In the rejection range, the cutting plan is adjusted according to the scrap position. However, this can only be done within preset product boundaries or by replacing the planned product by a standardized stock length.
In the event of a deviation from the projected product quality, the product is produced at the projected size but cannot be used for the customer order.
Because in this case the resulting product cannot be directly distributed to the customer order, the operator can incur the cost of rework, storage, lost production, and/or scrapped.
Production plans are currently created in advance and only then are the reactions to plan deviations taken into account in the planning system.
During the manufacturing of the semi-finished product, i.e. before the product is cut, the production plan has no dynamic response to production events. Deviations from the production plan can be formed by process events, quality deviations or deviations within the product width.
Process events are events that depend on operation. This can be, for example, a replacement of the tundish, a replacement of the dip tube or other maintenance measures. These process events have an influence on the product quality, and these areas have to be cut out of the casting strand, so-called scrap. Here, attempts are made to vary the product within the planned minimum and maximum dimensions of the product by optimizing the cutting length such that the waste part is located at the end of the product. Depending on the length of the reject fraction, either it is cut directly or the product length is extended by the length of the reject fraction.
If optimization cannot be performed within product boundaries, the planned product will be replaced by a substitute product until a solution with as high a yield as possible is achieved. Here, since this is an unintended production, these products must be temporarily stored.
The quality deviation can be determined by online quality prediction of a 2-level system. In this case, the product may be devalued and not later rescheduled to another customer order.
If the die format cannot be set to a desired width due to process conditions or disturbances, a product width deviation occurs that cannot be eliminated in the subsequent production process. Such deviations in product width do not initially result in any changes to the product plan. The product is produced with the originally planned target length. One exception here is weight optimization calculations, where slab length is adjusted to achieve the planned product weight. However, this is rarely used.
CN105243512A shows a dynamic production plan for the operation of a steel mill.
CN1556486A discloses an integrated online planning and delivery date making system and method for the production process of steel companies.
Document DE 10047381 A1 discloses a method for operating a plant in the basic material industry, in which products assigned to different production orders are produced. And creating a production plan by using program steps of order selection, preplanning, optimization and the like.
Disclosure of Invention
The object of the present invention is to provide a method which ensures as cost-effective a production as possible with a minimum of waste and reduced storage costs.
This object is achieved by the initially mentioned method comprising the following:
-comparing the nominal production parameter with the actual production parameter.
-creating a casting flow map from the actual production parameters if the nominal production parameters deviate from the target production parameters. The strand image comprises the cast strand that has been cast and has not yet been cut, and the strand that is produced at least as a function of the residual weight in the tundish and the predefined parameters.
-checking in a preset production plan, if possible, creating a new production plan, based on the calculated casting flow map.
-transferring the casting image to a production planning system if a solution cannot be found from a pre-set production plan.
-the production planning system creating a new production plan from all existing orders according to preset optimization criteria.
-then transmitting the new production plan to the production system.
Deviations in production are determined by comparing nominal and actual production parameters. Furthermore, the setpoint and actual production parameters and the setpoint production parameters are parameters of the continuous casting installation and/or parameters characterizing the casting process of the continuous casting installation. Examples of such actual production parameters are casting speed of the strand, casting level, mold width, parameters of strand cooling, temperature of the melt and/or casting powder thickness. In the case of deviations, the casting flow map is then formed from the different parameters. These parameters are, for example, the width profile of the cast strand, the width profile in the tundish, the length, the scrap position, the target quality of the product to be preset and many other parameters.
The casting-strand map includes the casting strand that has been cast to a so-called zero point. Ideally, the zero point is the achieved cutting edge of the as-cast strand. However, the zero point can also be behind the cutting edge. Depending on the extent to which it is still possible to react to the determined production deviations. This is therefore dependent on the reaction time of the respective system, for example when the flame cutter commands a cut, which cannot be cancelled anymore due to the reaction time of the respective system. Furthermore, the casting flow map comprises portions generated according to the production parameters and the remaining weight in the casting tundish. This is a prediction based on known parameters. From this casting flow map, a solution can be sought in a preset production plan. If a solution cannot be derived therefrom, the casting flow image is transferred to a production planning system. All existing orders are collected in the production planning system. Matching orders can be found by comparison with the cast stream map. New production plans can be created by optimizing criteria such as the highest possible sales revenue with the shortest storage period and the highest possible sales revenue with low priority but appropriate orders being prearranged. The new production plan is then sent to the production system. The new production plan replaces the pre-set production plan and the cast strand is then cut and/or produced according to the new production plan. The production plan contains at least one desired product dimension, such as nominal, minimum, maximum length, width, thickness. Other plant specific information such as customer order number, target quality, destination are also included.
An advantageous embodiment provides that the casting flow map is formed from at least one of the following parameters:
width profile on the strand
-a width profile in the casting tray,
-the position and length of the scrap,
-a prediction of the quality of the cast strand,
-product limitations of a product-specific computing solution,
-a preset target quality of the product.
The width profile on the strand includes the width of the strand and the location of the width variation. The width profile in the tundish no longer contains width specifications that can be changed. The scrap position and length are the position and length of the scrap in the casting strand, which occurs, for example, when changing the tundish. A mass prediction of the cast strand is calculated from a mass prediction model of any of the cast strand segments. Product limitations of product-specific computational solutions include current solutions to the computation of cut locations by production systems. The preset target quality of the product comprises a specified target quality of a solution calculated for the product specification.
A preferred embodiment provides that a unique key, preferably a hash code, is calculated from the casting image and that the key is used in the data exchange with the production system and the production planning system. This unique key enables a very quick determination of whether the data associated with the cast stream image has changed between two calculation cycles. Another advantage of the unique key is that the key may be used to determine whether the correct casting image is stored when a new production plan is transmitted. Errors can be identified by deviations in the key sent to and subsequently transmitted by the production planning system to the production system. When transferred, it can also happen that the newly created production plan is no longer valid, because the cast stream image has changed again during this time. This situation can be directly identified by a unique key.
Hash code calculation as an example of a key:
Figure BDA0003878735820000061
an advantageous embodiment provides that the optimization criterion is as high sales revenue as possible with as short a storage period as possible or as high sales revenue as possible with a lower priority order being prearranged.
An advantageous embodiment provides that the connection between the production system and the production planning system is a decoupled bidirectional connection. By means of the decoupled system it is ensured that production continues during the search for a new production plan in the production planning system. This is done according to the last pre-set efficient production plan. The production planning system independently looks for a solution to the optimization problem without stopping or modifying the current production in any way. Changes will only occur when a new production plan is transferred to the production system.
An advantageous embodiment provides that the production plan is a cutting plan with a desired length, minimum length, maximum length, width and/or thickness.
The object is also achieved by the continuous casting installation mentioned at the outset, which has at least one computer system for carrying out the method described above. The advantages already described above are achieved by the continuous casting installation.
An advantageous embodiment provides that the continuous casting installation has a first computer system for the production system and a second computer system for the production planning system. The first computer system and the second computer system are connected to each other through a decoupled bidirectional connection.
The object is also achieved by a computer program comprising instructions for causing the aforementioned continuous casting installation to perform the method steps according to the aforementioned method.
Drawings
Fig. 1 shows a schematic view of a continuous casting installation.
FIG. 2 shows a casting strand with associated quality information.
Figure 3 shows an activity diagram of the method.
Detailed Description
Fig. 1 schematically shows a continuous casting installation 1. Liquid metal 6 is poured into the mould 2 and the cast strand 7 is then removed from the mould 2. The production system 3 is implemented on a computer system. By means of the production system 3 with the process and model calculations 3a and the storage system 3b, data with the position at which the torch-cutter 10 will cut the cast strand 7 is transmitted to the programmable logic controller 5 a. The production system 3 receives input parameters from the production planning system 4 and the adjustment and control system 5. Production planning system 4 is also implemented on a computer system. On the one hand, these input parameters can be transmitted via data lines 8 from the programmable logic controller 5a and/or from a high-level control system of the industrial installation. The programmable logic controller 5a is connected to the measuring instrument 5b and/or the control element 5 c. The parameters detected by the measuring instrument 5b are, for example, the measured strand dimensions, the melt temperature, the casting speed and/or the parameters of the cooling strand. The composition of the melt is submitted to the production system 3 or can be retrieved from the memory 3 b. When deviations of the actual values from the nominal values are determined in production, for example by the production system 3, a casting map is calculated and the production system 3 attempts to adjust the preset production plan to compensate for these deviations. The actual parameters are calculated by process and model calculations 3 a. If this is not possible, the casting image is transmitted to the production planning system 4 via the decoupled bidirectional connection 9. The system retrieves existing customer orders from the order book 4b and attempts to create a new production plan based on the parameters stored in the production planning computer 4 a. Once the new production plan is derived, it is transferred from production planning system 4 to production system 3.
In fig. 2a casting strand 7 is shown which can be present in production. The casting direction is here to the left from the mold position 25. The casting strand 7 has a cutting edge 21 representing a feasible zero point. This zero point can also be located further back due to processing time. The section that cannot be used for further production is the reject area 22.
The width change region 23 occurs when the width setting of the die is increased or decreased. A range of width ranges 24 representing the change then appears. The area from the cutting edge 21 to the die position 25 represents the area that has been cast. The width variation zones 26 and the residual zones 27 represent those zones produced by the residual amount of liquid metal in the tundish. Thus, these two regions are only generated when viewed.
The calculated actual mass of each strand section is shown in the mass prediction 30. The target quality 31 describes a quality that should be produced originally by a preset production plan. As can be seen from the comparison of the quality prediction 30 and the target quality 31, they do not match and therefore a new production plan is created.
Fig. 3 shows an activity diagram. The production plan is always updated in step S1. In the next step S2, a cutting plan is calculated from the production plan. If no deviation is determined in the case of query Q1, step S10 is entered, in which the corresponding cutting lengths are preset and transmitted from the production system 3 (2-stage system) to the torch-cutter. If there is a discrepancy, step S4 is initiated in query Q1, creating a casting image. The created casting flow image is checked in step S5, and in the case of a discrepancy in the query Q2, step S6 is introduced, which creates a request message and transmits it to the production planning system 4. The connection between the production system 3 and the production planning system 4 is advantageously realized by a decoupled bidirectional connection 9. In an advantageous embodiment, the request message contains a calculated unique key, which is then used as an identification in a further data exchange between the production system 3 and the production planning system 4. This key can be used to quickly determine if the relevant data has changed between calculation steps. This request message is used by the production planning system 4 in step S7, and a check of the entire order book is performed in step S7 in accordance with this request message. It is checked in query Q3 whether a matching customer order is found. If this is the case, a production plan update is created in step S8 and the response message is transmitted to the production system 3. If no matching customer order is found in query Q3, no production plan update will be created. In this case, the production system 3 continues to operate with the initially preset production plan, or the production system changes the production plan according to other specifications. If a production plan update has been created, it is transmitted from the production planning system 4 to the production system 3 by a response message via the decoupled bidirectional connection 9. In step S9, it is checked, for example, at the production system 3 whether the transmitted response message has, for example, the same key as the request message. Then, in query Q4, it is determined whether the data is valid, and if so, a new cutting plan is calculated in step S2. If the data in query Q4 is deemed invalid, the data is not sent to step S2. Then, as with query Q3, the operation continues according to the original production plan, or the production plan is modified according to other specifications. This can be achieved, for example, by presetting the length of the reject or the standard length placed in the warehouse for a particular quality.
Although the invention has been illustrated and described in detail by the preferred embodiments, the invention is not limited to the disclosed examples and other variants can be derived therefrom by the person skilled in the art without departing from the scope of the invention.
List of reference numerals
1. Continuous casting installation
2. Die set
3. Production system
3a Process and model calculation
3b memory
4. Production planning system
4a production plan calculation
4b order book
5. Regulating and/or controlling system
5a programmable logic controller
5b measuring instrument
5c control element
6. Liquid metal
7. Casting flow
8. Data line
9. Decoupled bidirectional connection
10. Flame cutting machine
21. Cutting edge
22. Waste area
23. Range of width variation
24. Extent of variation of width
25. Mold position
26. Region of varying width
27. Residual region
30. Quality prediction
31. Target mass
S1-S10 steps
Q1-Q4 queries.

Claims (10)

1. A dynamic production planning method for a continuous casting plant (1) for casting a cast strand (7) with a production system (3) having a preset production plan, the method comprising:
-comparing the nominal production parameter with the actual production parameter,
-creating a strand map from the actual production parameters if the actual production parameters deviate from the nominal production parameters, wherein the strand map comprises a cast strand (7) that has been cast but not yet cut and at least a cast strand (7) obtained from a residual weight in a casting tundish and preset parameters,
-checking within a preset production plan and creating a new production plan if feasible, based on the calculated casting flow image,
-transferring the casting flow image to a production planning system (4) if no solution can be found from the preset production plan,
-the production planning system (4) creating a new production plan from all existing orders according to preset optimization criteria,
-transmitting the new production plan to the production system (3).
2. The dynamic production planning method for a continuous casting plant (1) for casting a strand (7) according to claim 1, characterized in that the strand map is formed by at least one of the following parameters:
-a width profile of the cast strand,
-a width profile in the casting tray,
-the position and length of the scrap,
-a prediction of the quality of the cast strand,
-product restrictions for product specifications of the calculated solution,
-a preset target quality of the product.
3. The dynamic production planning method for a continuous casting plant (1) for casting a strand (7) according to claim 1 or 2, characterized in that a unique key, preferably a hash code, is calculated from the strand image and used in the data exchange with the production system (3) and the production planning system (4).
4. A dynamic production planning method for a continuous casting plant (1) for casting a cast strand (7) according to claims 1-3, characterised in that the optimization criterion is as high sales revenue as possible with as short a storage period as possible or as high sales revenue as possible with low priority orders scheduled in advance.
5. The dynamic production planning method for a continuous casting plant (1) for casting a cast strand (7) according to claims 1-4, characterized in that the connection between the production system (3) and the production planning system (4) is a decoupled bidirectional connection (9).
6. The dynamic production planning method for a continuous casting plant (1) for casting a cast strand (7) according to claims 1-5, characterized in that the production plan is a cutting plan with a nominal length, a minimum length, a maximum length, a width and/or a thickness.
7. The dynamic production planning method for a continuous casting plant (1) according to claims 1-6 for casting a strand (7), characterized in that the actual production parameter and the nominal production parameter are the casting speed of the strand, the casting level, the mold width, the parameters of the strand cooling, the temperature of the melt and/or the casting powder thickness.
8. A continuous casting plant (1) comprising at least one computer system for performing the method according to claims 1-7.
9. The continuous casting plant according to claim 8, characterized in that the continuous casting plant has a first computer system for a production system (3) and a second computer system for a production planning system (4), wherein the first computer system and the second computer system are connected to each other by a decoupled bidirectional connection (9).
10. A computer program comprising instructions for causing a continuous casting plant (1) according to claim 8 or 9 to carry out the steps of the method according to claims 1-7.
CN202180027122.8A 2020-04-09 2021-04-08 Dynamic production planning method for continuous casting facility Pending CN115427903A (en)

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PCT/EP2021/059193 WO2021204950A1 (en) 2020-04-09 2021-04-08 Dynamic production planning method for continuous casting plants

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